Silicone-Containing Roof Assemblies and Methods for Production and Use

ABSTRACT

An underlayment material has a fiber mat partially infused and/or coated with asphalt and coated with silicone coating. A selvedge edge, may be coated or uncoated. The back of the underlayment has a self-adhesive coating, which is protected before use by a siliconized release film. The upper surface of the underlayment is coated with silicone composition providing waterproofing and radiation control. When unsaturated, the selvedge edge of fibrous material establishes a reinforced bond with an overlying sheet. When saturated with asphalt, the bond at the selvedge edge between adjacent sheets is between the asphalt layer of the selvedge edge and the adhesive on the bottom of the adjacent sheet.

FIELD

The present invention relates to roofing materials, and moreparticularly, to a roofing material that may be used as underlayment forexterior roofing layers, such as ceramic tiles, wood shakes, metal,slate or asphalt shingles or as the exterior layer itself.

BACKGROUND

Roofing materials need to be waterproof and are frequently used inmultiple layers to convey a redundant water barrier. Underlaymentmaterials are known which are applied to roof decking to provide a firstlayer of water-proofing. Additional roofing layers, such as roofingtiles, shingles, or asphalt roll roofing are then applied over theunderlayment in order to increase the weather resistance of the roof andto achieve aesthetic effects. While various types of underlayment andfinish roofing layers are known, additional alternatives remaindesirable.

SUMMARY

The disclosed subject matter relates to a method for making a buildingmaterial, comprising the steps of providing a web of support material ina roll; withdrawing the support material from the roll; coating thesupport material with a silicone material; curing the silicone materialto a non-tacky condition; winding the coated support material on atake-up roll.

In another embodiment, the silicone material is water-curable and thestep of curing includes applying water to the silicone material.

In another embodiment, further including the step of allowing the waterto remain in contact with the silicone material for a period of timethat initiates curing.

In another embodiment, further including the step of removing the waterfrom the silicone material after initiation of curing.

In another embodiment, further including the step of adding a catalystto the silicone material to increase the rate of curing.

In another embodiment, the catalyst is an organo-metallic compound.

In another embodiment, the catalyst is dibutylin dilaurate present in aconcentration of 0.1 to 1.0% by weight in the silicone material.

In another embodiment, the silicone material is applied at a thicknessin the range of 0.1 mm to 2 mm.

In another embodiment, the silicone material has a viscosity in therange of 1,000 to 20,000 cps during the step of applying,

In another embodiment, further including the step of applying a modifiedasphalt to the support material prior to the step of coating with thesilicone coating.

In another embodiment, the modified asphalt is imbedded into the supportmaterial by dip-saturation or squeezing prior to the step of coatingwith the silicone material.

In another embodiment, the modified asphalt is applied to an uppersurface of the support material.

In another embodiment, further including the step of applying anadhesive to a bottom surface of the support material.

In another embodiment, further including the step of forming a selvedgeedge by scraping modified asphalt from a portion of the supportmaterial.

In another embodiment, further including the step of applying a releasesheet to the adhesive applied to the bottom surface.

In another embodiment, the silicone material is applied to a portion ofthe support material leaving a selvedge edge uncoated.

In another embodiment, further including the step of applying anadhesive to a selvedge edge of the support material.

In another embodiment, further including the step of applying a releasesheet over the adhesive on the selvedge edge.

In another embodiment, the silicone material is first prepared in anatmosphere of nitrogen prior to the step of applying the siliconecoating.

In another embodiment, the step of applying and curing are conducted ona roll line that advances at a rate of about 50 to 300 feet per minute.

In another embodiment, the curing occurs within 10 minutes.

In another embodiment, the step of applying water is by misting with aspray conducted in less than 10 minutes.

In another embodiment, the step of removing water is conducted byblowing air on the building material.

In another embodiment, a building material with an upper surface and alower surface has a support web at least partially infused with asphalt;a layer of silicone material applied to at least one of the support webor the asphalt, covering at least a portion of the upper surface anddefining a selvedge edge on the upper surface that is not covered by thesilicone material.

In another embodiment, the asphalt is modified and contains at least oneof SBS, APP, SIS, SEB, SEBS or a combination of homo, block orco-polymers.

In another embodiment, further including a layer of adhesive applied toa bottom surface.

In another embodiment, further including a release sheet removablycovering the adhesive on the bottom surface.

In another embodiment, the support web is made from a fibrous material.

In another embodiment, the fibrous material includes at least one ofpolyester, fiberglass, a combination of fiberglass and polyester,asphalt saturated felt-paper, Polypropylene, Polyethylene, or acombination of Polypropylene and Polyethylene.

In another embodiment, the building material has a weight per squarefoot in the range of 0.1 to 1.0 lbs./ft².

In another embodiment, the building material has a weight per squarefoot in the range of 0.1 to 0.55 lbs./ft².

In another embodiment, the building material has the followingproperties: tensile strength MD/CD (psi) 66/30; elongation MD/CD (%)226/275; density of about 0.971 bs/yard²; tear strength MD/CD(psi) of55/85 and adhesion to plywood(plf)) of about 28.

In another embodiment, the method includes applying a modified asphaltto the support material after the step of coating with the siliconecoating.

In another embodiment, the asphalt in the building material isun-modified.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, referenceis made to the following detailed description of exemplary embodimentsconsidered in conjunction with the accompanying drawings.

FIG. 1 is diagrammatic view of an apparatus and process for making aroofing underlayment material in accordance with an embodiment of thepresent disclosure.

FIG. 2 is a diagrammatic cross-sectional view of a mat component of anunderlayment material in accordance with an embodiment of the presentdisclosure.

FIG. 3 is a diagrammatic cross-sectional view of a coated mat componentof a underlayment material in accordance with an embodiment of thepresent disclosure.

FIG. 4 is a diagrammatic cross-sectional view of a coated mat componentof a underlayment material with infused mat and selvedge edge inaccordance with an embodiment of the present disclosure.

FIG. 5 is a diagrammatic cross-sectional view of the coated matcomponent of FIG. 4 with adhesive layers applied in accordance with anembodiment of the present disclosure.

FIGS. 6 and 7 are diagrammatic cross-sectional views taken of the coatedmat component of FIG. 1 along section lines 6-6 and 7-8 of FIG. 1,respectively and looking in the direction of the arrows, with adhesivelayers covered by release sheets applied in accordance with anembodiment of the present disclosure.

FIG. 8 is a diagrammatic cross-sectional view of the coated matcomponent of FIGS. 6 and 7 with a layer of silicone material applied inaccordance with an embodiment of the present disclosure.

FIG. 9 is diagrammatic view of an apparatus and process for making aroofing underlayment material in accordance with an alternativeembodiment of the present disclosure.

FIG. 10 is a diagrammatic cross-sectional view of a mat component of anunderlayment material in accordance with an embodiment of the presentdisclosure.

FIG. 11 is a diagrammatic cross-sectional view of a coated mat componentof a underlayment material in accordance with an embodiment of thepresent disclosure.

FIG. 12 is a diagrammatic cross-sectional view of a coated mat componentof a underlayment material with partially infused mat in accordance withan embodiment of the present disclosure.

FIG. 13 is a diagrammatic cross-sectional view of the coated matcomponent of FIG. 12 with an adhesive layer applied in accordance withan embodiment of the present disclosure.

FIG. 14 is a diagrammatic cross-sectional view taken of the coated matcomponent of FIG. 13 taken along section line 14-14 shown in FIG. 9 andlooking in the direction of the arrows, with a release sheet applied inaccordance with an embodiment of the present disclosure.

FIG. 15 is a diagrammatic cross-sectional view of the coated matcomponent of FIG. 14 taken along section line 15-15 in FIG. 9 andlooking in the direction of the arrows, with a layer of siliconematerial applied in accordance with an embodiment of the presentdisclosure.

FIG. 16 is a diagrammatic view of an apparatus and process for making aroofing underlayment material in accordance with an alternativeembodiment of the present disclosure.

FIG. 17 is a diagrammatic cross-sectional view of an underlaymentmaterial in accordance with an embodiment of the present disclosuretaken along section line 17-17 and looking in the direction of thearrows.

FIG. 18 is a diagrammatic cross-sectional view of an underlaymentmaterial in accordance with an embodiment of the present disclosuretaken along section line 18-18 and looking in the direction of thearrows.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG. 1 shows a manufacturing line 10 for making an underlayment material50 in accordance with an embodiment of the present disclosure. A wovenor felted polyester mat 12, having an initial thickness of about 0.5 mmto 1.6 mm or, in one embodiment, 0.8 mm-1.2 mm, and a density of about40 g/m² to 250 g/m² or, in one embodiment, 120 g/m² to 190 g/m² and awidth of about 32 in to 42 in or, in one embodiment, 1 m to 36 in, iswithdrawn from a supply roll 14 by the action of one or more rolls 16,18A, 18B, 24A, 24B, 28A, 28B, 34A, 34B, 34C, 46, 48A, 48B, 54, 58, 60,62, which may be driven by an electric motor or the like, and/or turnedby the passage of the mat 12 passing there over. Some or all of therolls 16, 18A, 18B, 24A, 24B, 28A, 28B, 34A, 34B, 34C, 48A, 48B, etc.,may be free-wheeling. Rolls, such as support rolls 16 and 54 may be usedto support the mat 12 as it travels a distance to the next set of rolls,e.g., 18A, 18B. Rolls 46, 58 and 60 may be used to change the directionof the mat 12, induce advancement of the mat 12 and/or providetensioning. In addition to rolls, e.g., 16, support belts, tables, etc.may also be used in guiding, supporting and handling the mat 12, both atthe initial stage and at later stages.

FIG. 2 shows a cross-sectional view of the mat 12, which may be obtainedfrom Johns Manville of Denver, Colo., USA as products identified asspunbond/needle punched and/or glass reinforced mat, or from a varietyof other sources. As an alternative to polyester, the mat 12 may be madefrom other materials, such as fiberglass, a combination of fiberglassand polyester, asphalt saturated felt-paper, polypropylene,polyethylene, or a combination of polypropylene and polyethylene. FIGS.2-6 are cross sections from the same perspective, i.e., cutting throughthe reflective element in a direction parallel to its direction ofadvancement and looking perpendicular to the direction of advancement(into the page.) The same can be said of FIG. 10-14.

Referring back to FIG. 1, after withdrawal from the supply roll 14, themat 12 passes to a styrene butadiene styrene (SBS) modified asphaltcoating station 18 having coating rolls 18A, 18B, 18C, the latter ofwhich rotates in liquefied coating 18D1 held in reservoir 18E1 and thenwith roll 18B passes the SBS modified asphalt coating 18D1 to the bottomsurface of the mat 12. The upper surface may also optionally be coatedby roll 18A which is fed a supply of coating 18D2 by reservoir 18E2. TheSBS modified asphalt coating is of a type that is well known in theindustry and may be obtained commercially or may be produced on site.The SBS modified asphalt coating 18D1 is kept in a liquid state bymaintaining it at a temperature of about 325-380° F.

FIG. 3 shows the SBS modified asphalt coated mat 20 in cross-section andhaving three layers: an optional upper layer of SBS modified asphaltcoating 20A having an applied thickness of about 0 mm to 2 mm, in oneembodiment, 0.3 mm to 0.5 mm, a lower layer of SBS modified asphaltcoating 20B with an applied thickness of about 0.1 mm to 2 mm, in oneembodiment, 0.3 mm to 0.5 mm, and middle mat layer 20C about 0.5 mm to1.6 mm, in one embodiment, 0.8 mm to 1.2 mm thick. Referring to FIG. 1,a doctor blade 22 may optionally be used to scrape a portion of the SBSmodified asphalt upper layer 20A (FIG. 3), e.g., of a width of about 3inches to 3.5 inches and a depth of about 0.3 mm to 0.5 mm to form aselvedge edge 26AS, as shown in FIG. 4. The applied SBS coating layer(s)20B and optionally 20A, when hot, wick into the mat layer 20C and thevolume of SBS necessary to saturate the mat layer 20C may be adjusted byadjusting the applied thickness, Referring to FIG. 1, a compressionstation 24 with an upper roll 24A and a lower roll 24B may be utilizedto squeeze the SBS upper and lower coatings 20A, 20B into the mat layer20C and/or to reduce the thickness of the coated mat 20 (FIG. 3) to adesired thickness, producing the compressed, coated mat 26 (FIG. 4). Asthe SBS cools, it is retained in the middle mat layer 20C and the coatedmat 26 exhibits dimensional stability. In one example, the compressedmat 26 has an upper SBS layer 26A of about 0 mm to 2 mm, in oneembodiment, 0.3 mm to 0.5 mm in thickness, a selvedge edge 26AS of about0 mm to 2 mm, in one embodiment, 0.3 mm to 0.5 mm thickness, a lower SBSlayer 26B of about 0.1 mm to 2 mm, in one embodiment, 0.3 mm to 0.5 mm,in thickness and an SBS infused mat middle layer 26C of about 0.5 mm to1.6 mm, in one embodiment, 0.8 mm to 1.2 mm in thickness, such that thetotal thickness of the compressed mat 26 when measured at the thickestpart is about 1.5 to 2.5 mm. When additional layers, e.g., of adhesiveand release film are added, as described below, the total thickness willincrease, in one example to about 2 to 3.5 mm thickness depending uponwhere the measurement is made, e.g., at or beyond the selvedge edge26AS. These dimensions are merely exemplary and may be variedconsiderably, e.g., depending upon the strength and weight that isdesired/required in the final underlayment product 50. For example,underlayment that is subjected to severe weather may need to besignificantly thicker and stronger than that which is used in mildclimates. In addition, a range of qualities are generally offered havingvarying useful lifetimes and warranties. Weight limitations andpreferences pertaining to ease of transporting material to a roof mayalso play a part in matching the dimensions of the underlayment 50 togiven needs or preferences of the consumer. In light of these factors,the total thickness of the underlayment product may vary widely.

Referring to FIG. 1, the upper roll 24A may optionally have acylindrical portion 24AC of greater radius to insure that the selvedgeedge 26AS is rolled to a consistent and smooth thickness that is lessthan the thickness of the remainder of the compressed mat 26. Anadhesive applying station 28 with applying rolls 28A (optional), 28B,28C and optional doctor blade(s) 30 (only one shown) may be used toapply self-adhering adhesive (SA) 28D held in reservoir 28E to thecompressed mat 26, yielding an adhesive coated web 32. The adhesive 28Dmay be prepared on-site by combining SBS rubber and asphalt or may beobtained commercially from a variety of sources, e.g., from Crafco, Inc.of Chandler, Ariz. A filler may be added to increase durability. In oneexemplary embodiment, the adhesive will have the following weightpercentages: about 4% to 8% SBS rubber, about 50% to 60% asphalt of the150-200 pen type and about 15% to 25% filler in the form of calciumcarbonate/limestone.

FIG. 5 shows the adhesive coated web 32 having an upper layer 32A withselvedge edge 32AS, a lower layer 32B, an infused middle layer 32C, anadhesive layer 32D on selvedge edge 32AS and a bottom adhesive layer32E. It should be appreciated that the optional adhesive 32D on theupper side of the adhesive coated mat 32 would be applied only to theselvedge edge 32AS and that the bottom layer of adhesive 32E may coverthe entire bottom surface of the adhesive coated web 32.

Referring to FIG. 1, after application of the adhesive layer 32E andoptionally adhesive layer 32D, the adhesive coated web 32 may be cooledby a cooling station 31, such as a water bath. A release filmapplication station 34 with application rolls 34A, 34B, 34C (optional)may be used to apply a split, siliconized, polyethylene bottom releasefilm 36 of about 1.0 to 1.5 mm in thickness to cover the bottom adhesivelayer 32E. Such film is available commercially from a variety ofsources, e.g., Integrated Films of Atlanta, Ga. and is deployed from abottom film roll 38 and drawn with the adhesive coated mat 32 betweenthe rolls 34A, 34B. A siliconized, polyethylene selvedge edge releasefilm 40 drawn from selvedge edge film roll 42 may optionally besimilarly applied over the adhesive layer 32 D on the selvedge edge 32ASand pressed into position by rolls 34B, 34C, producing protected,self-adhesive web 44. If the selvedge edge 32AS is coated with anadhesive, the release film 36 on the bottom of the adhesive coated mat32 will prevent the selvedge edge 32AS from sticking to other parts ofthe mat 32 when the mat 32 is rolled and a release sheet is typicallynot required to cover the selvedge edge 32AS, however, for purposes ofpreserving the cleanliness and flatness of the selvedge edge, a releasesheet may be used. As shown in FIGS. 6 and 7, the protected, selfadhesive web 44 has an upper layer 44A, a selvedge edge 44AS, a lowerlayer 44B, an infused middle layer 44C, an adhesive layer 44D (optional)on the selvedge edge 44AS, a bottom adhesive layer 44E, a release film44F (optional) on the selvedge edge 44AS adhesive layer 44D and a bottomrelease film 44G covering bottom adhesive layer 44E.

Referring to FIG. 1, the protected, self-adhesive web 44 optionallypasses over a support/direction change roll 46 and into a siliconecoating station 48 with an upper coating roll 48A and a lower supportroll 48B that applies a silicone coating 48C on the top of the web 44 toyield a silicone coated web 50. The silicone coating 48C may be preparedstarting with a commercially available moisture-curable siliconecoating, such as Eterna-Kote S-100 Silicone Roof Coating available fromSun Paints and Coatings Inc. of Clearwater, Fla. or another comparable,commercially available coating. The silicone coating is of a type thatis moisture curable within a relatively fast curing time, e.g., 2 to 4hours at 50% humidity, with full cure occurring in 24 to 48 hours at 50%humidity. In accordance with an aspect of the present disclosure, thecommercially available silicone coating is modified by: 1) adding aquantity of catalyst of the organometallic compound type, e.g.,dibutyltin dilaurate, in an amount of 0.1% to 1% by weight to allowcuring of an applied layer of the silicone coating in a timeframeconsistent with use on a fast-paced commercial production line using themethods and apparatus disclosed below. The viscosity is also adjusted topermit efficient application by the methods described below.

Preparation of the Silicone Coating

A silicone coating made in accordance with the foregoing formula may bemade by the mixing in a vacuum mixer and packaged. Optionally, themixing and packaging may be conducted in a nitrogen atmosphere or otherdry atmosphere to reduce moisture exposure.

Use/Application of the Silicone Coating

The silicone coating which has a viscosity adjusted to the range of1,000 to 20,000 cps in one embodiment and 4,000 cps to 6,000 cps inanother embodiment, volatile organic compound content (VOC) of <10 (g/L)may be applied by roller coating, spraying, slot dye extrusion,electrostatic coating, etc. to form a layer of about 0.1 mm to 6 mm, inone embodiment, about 0.1 mm to 2.0 mm thick in another embodiment and0.3 mm to 2 mm, thick in another embodiment on the coated web 50. Adoctor blade (not shown) may be utilized to assure the thickness,evenness and flatness of the silicone coating layer 50H (FIG. 8).

Properties of the Silicone Coating and the Properties of theUnderlayment Material

When prepared/modified, applied and cured as described herein, thesilicone coating and underlayment material 50 has the followingproperties.

Silicone Coating

Property value Density (lbs/gal)  11.1 Low Temp Flex (−20° C. ) PassElongation (%) 300 Tensile Strength (PSI) 450 Shore Hardness A  55Solids (%) 100%

Underlayment Material

Property value Tensile MD/CD (psi)  66/30 Elongation MD/CD (%) 226/275Density (lbs/yrd²)  0.977 Tear MD/CD (psi)  55/85 Adhesion to Plywood(plf) 28

The silicone coating 48C (FIG. 1) is applied only to the upper surfaceof the protected, self-adhesive web 44 (FIGS. 6 and 7) and preferablynot on the selvedge edge 44AS. As shown in FIG. 1, an atomizer station52 with one or more atomizers 52A, 52B, 52C are utilized to spray a mistof water on the web 50 on top of the applied layer of silicone coating48C. In accordance with one example, a suitable atomizer may becommercially obtained from Exair under the brand name, Internal Mix FlatFan Atomizing Nozzles. The atomizers 52A, 52B, 52C mist the siliconecoating 48C applied to the web 50 with water in order to speed up thecuring reaction of the coating. The curing reaction (polymerization) iscatalyzed by water, so therefore a fine water spray is effective atinducing an even and complete cure of the coating 48C. One or moresupport rolls 54, belts or other support mechanism(s) maintains theposition of the silicone coated web 50 relative to the atomizers 52A-Cand relative to a drying/cooling station 56 with one or more fans 56A-E.The fans 56A-E will be used to evaporate any remaining moisture afterthe coating curing reaction has been completed. Optionally, an air knifemay be used to drive water off the web 50.

Additional support/redirecting rolls 58, 60 may be used to adjust thelength of the run of the silicone coated web 50 to allow curing of thesilicone coating and to deliver the web to a take-up roll/winder 62. Isshould be appreciated that the system 10 of FIG. 1 is not to scale andthat the distances between elements 14, 18, 24, 28 . . . 62 would be ofa different scale that that shown. In one example, the web 12 pathincludes passing through the SBS modified asphalt saturating station 18,the compression station 24, the adhesive applying station 28, thecooling station 31 and continuing on to the release film applicationstation 34. Following this, the web moves to the silicone coatingstation 48. The distance from the silicone coating station 48 to theatomizer station 52 is a short distance, e.g., from about 2 to 3 feet toallow the water mist time to cure the silicone coating 48C. In oneembodiment, the atomizer station 52 is about 6 to 8 feet long. Given aline speed of about 50-300 ft. per minute, in one example, it can beseen that the coating is misted within about 1 to 5 seconds after beingapplied to the silicone coated web 50 and for a duration of about 5 to10 seconds. This misting results in rapid curing of the coating, e.g.,in less than 100 seconds, or in a line distance of less than 500 ft. ata line speed of 300 ft./min or less than 160 ft. at a line speed of 100ft./min. In another embodiment, the misting is accomplished in less than10 minutes and the line speed may be adjusted to allow curing within alonger period of time, e.g., 10 minutes or less. The silicone coated web50 is then driven into the cooling/drying section 56. In this manner,the present disclosure illustrates how a silicone coated web 50 can beproduced in a high speed (100 to 300 feet per minute) manufacturingenvironment.

FIG. 8 shows the silicone coated web 50 in cross-section from the sameperspective as FIG. 7 and featuring an upper layer 50A, a lower layer50B, an infused middle layer 50C, a bottom adhesive layer 50E, a releasesheet 50F (shown by a dotted line) on the adhesive layer 50D (shown by adotted line) on the selvedge edge 50AS (shown by a dotted line), abottom release film 50G covering bottom adhesive layer 50E and asilicone coating layer 50H. It should be understood that the thicknessof the layers in FIGS. 2-8 and 10-15 are not to scale and arediagrammatic only.

FIG. 9 shows a manufacturing line 110 for making an underlaymentmaterial 150 in accordance with an alternative embodiment of the presentdisclosure. A woven or felted polyester mat 112, having an initialthickness of about 0.5 to 1.6 mm or, in one embodiment, 0.8 mm to 1.2mm, and a density of about 40 g/m² to 250 g/m² or, in one embodiment,120 g/m² to 190 g/m², and a width of about 32 in to 42 in or, in oneembodiment, 1 m to 36 in., is withdrawn from a supply roll 114 by theaction of one or more rolls 116, 118B, 124A, 124B, 128B, 134A, 134B,146, 148A, 148B, 154, 158, 160, 162, which may be driven by an electricmotor or the like, and/or turned by the passage of the mat 112 passingthere over. Some or all of the rolls 116, 118A, 118B, 124A, 124B, 134A,134B, 148A, 148B, etc., may be free-wheeling. Rolls, such as supportrolls 116 and 154, may be used to support the mat 112 as it travels adistance to the next set of rolls, e.g., 118B. Rolls 146, 158 and 160may be used to change the direction of the mat 112, induce advancementof the mat 112 and/or provide tensioning. In addition to rolls, e.g.,116, support belts, tables, etc. may also be used in guiding, supportingand handling the mat 112, both at the initial stage and at later stages.

FIG. 10 shows a cross-sectional view of the mat 112, which isessentially the same as that depicted in FIG. 2 and which may beobtained from Johns Manville of Denver, Colo., USA as productsidentified as spunbond/needle punched and/or glass reinforced mat, orfrom a variety of other sources. As an alternative to polyester, the mat112 may be made from other materials, such as fiberglass, a combinationof fiberglass and polyester, asphalt saturated felt-paper,polypropylene, polyethylene, or a combination of polypropylene andpolyethylene.

Referring back to FIG. 9, after withdrawal from the supply roll 114, themat 112 passes to a styrene butadiene styrene (SBS) modified asphaltcoating station 118 having coating rolls 118B, 118C, the latter of whichrotates in liquefied coating 118D held in reservoir 118E and then withroll 118B passes the SBS modified asphalt coating 118D to the bottomsurface of the mat 112. In this embodiment, the upper surface of the mat112 is not coated with SBS. The SBS modified asphalt coating is of atype that is well known in the industry and may be obtainedcommercially, e.g., from Crafco, Inc. of Chandler, Ariz. or may beproduced on site. The SBS modified asphalt coating 118D is kept in aflowable state by maintaining it at a temperature of about 325-380° F.

FIG. 11 shows the SBS modified asphalt coated mat 120 in cross-sectionand having two layers: a lower layer 120B of SBS modified asphaltcoating with an applied thickness of about 0 mm to 2 mm, in oneembodiment, 0.3 mm to 0.5 mm, and mat layer 120C about 0.5 mm to 1.6 mm,in one embodiment, 0.8 mm to 1.2 mm, thick. The applied SBS coatinglayer 120B is flowable when hot, and can wick into the mat layer 120C.If the viscosity of the SBS coating layer 120B is thin enough,attributable to temperature and composition, it may infuse into the matlayer 120C upon application. The volume of SBS necessary to saturate themat layer 120C to the desired extent may be adjusted by adjusting theapplied thickness. In this embodiment, the mat layer 120C may optionallybe less than fully saturated, such that an upper portion thereof is leftunsaturated with SBS, as shall be further described below.

Referring to FIG. 9, a compression station 124 with an upper roll 124Aand a lower roll 124B may be utilized to squeeze the SBS lower coating120B into the mat layer 120C to a selected extent and/or to reduce thethickness of the SBS coated/infused mat 120 (FIG. 11) to a desiredthickness, producing the compressed, coated mat 126 (FIG. 12). Thecompressed coated mat 126 features an upper un-infused layer 126C of matwithout SBS, a middle layer 126D of mat saturated with SBS and a lowerlayer 126B of SBS that has not been absorbed into the mat 112 (FIG. 10).The lower layer 126B may have various thicknesses ranging from 0.1 mm to2 mm, in one embodiment, 0.3 mm to 0.5 mm, and may have effectively zerothickness if the entire applied coating of SBS 120B (FIG. 11) isinfused/pressed into the mat 112 (FIG. 10) to form the middle layer 126D(FIG. 12). As the SBS cools, it is retained in the mat layer 126D andthe coated mat 126 thereafter exhibits dimensional stability. In oneexample, the compressed mat 126 has an upper un-infused mat layer 126Cabout 0 mm to 2 mm, in one embodiment, 0.3 mm to 0.5 mm in thickness, acenter infused mat layer 126D about 0.5 mm to 1.6 mm, in one embodiment,0.8 mm to 1.6 mm in thickness and a lower SBS layer 126B of about 0.1 mmto 2 mm, in one embodiment, 0.3 mm to 0.5 mm, in thickness, such thatthe total thickness of the compressed mat 126 in one example is about1.5 to 2.5 mm. When additional layers, e.g., of, e.g., adhesive andrelease film are added, as described below, the total thickness willincrease, in one example to about 2 to 3 mm thickness. These dimensionsare merely exemplary and may be varied considerably, e.g., dependingupon the strength and weight that is desired/required in the finalunderlayment product 150 (FIG. 15) and to satisfy the needs orpreferences of the consumer. In light of these factors, the totalthickness of the underlayment product may vary widely, e.g., from 1.5 mmto 3 mm in total thickness.

An adhesive applying station 128 with applying rolls 128B, 128C andoptional doctor blade(s) 129 may be used to apply self-adhering adhesive(SA) 128D held in reservoir 128E to the compressed mat 126 yielding anadhesive coated web 130. In this embodiment, the adhesive is appliedonly to the back of the compressed mat 126. The adhesive 128D may beprepared on site by combining SBS rubber and asphalt or may be obtainedcommercially from a variety of sources, e.g., from Crafco, Inc. ofChandler, Ariz. A filler may be added to increase durability. In oneexemplary embodiment, the adhesive will have the following weightpercentages: about 4% to 8% SBS rubber, about 50% to 60% asphalt of the150-200 pen type and about 15% to 25% filler in the form of calciumcarbonate/limestone.

FIG. 13 shows the adhesive coated web 130 having an upper un-infusedlayer 130C, an infused middle layer 130D, a lower SBS layer 130B, and abottom adhesive layer 130E, which may cover the entire bottom surface ofthe adhesive coated web 130.

Referring to FIG. 9, after application of the adhesive layer 130E, theadhesive coated web 130 may be cooled by a cooling station 131, such asa water bath 131. A release film application station 134 withapplication rolls 134A, 134B may be used to apply a split, siliconized,polyethylene bottom release film 136 of about 1.0 to 1.5 mm in thicknessto cover the bottom adhesive layer 130E, producing protected,self-adhesive web 144. Siliconized, polyethylene release film isavailable from a variety of commercial sources, such as Integrated Filmsof Atlanta, Ga. and is deployed from a bottom film roll 138 and drawnwith the adhesive coated mat 132 between the rolls 134A, 134B. As shownin FIG. 14, the protected, self adhesive web 144 has an upper layer 144Cof un-infused web, a middle SBS-infused layer 144D, an SBS layer 144B,an adhesive layer 144E and a release film 144F covering bottom adhesivelayer 144E.

Referring to FIG. 9, the protected, self-adhesive web 144 optionallypasses over a support/direction change roll 146 and into a siliconecoating station 148 with a lower support roll 148B and an upper coatingroll 148A that applies a silicone coating 148C to a portion of the uppersurface 144C of the self-adhesive web 144 to yield a silicone coated web150 (FIG. 15). As noted, only a portion of the width of theself-adhesive web 144 is coated with silicone and the portion thatremains uncoated forms a selvedge edge 150SE. Since the selvedge edge150SE is uncoated with silicone coating and may have exposed fibers thatare not infused with SBS, it will form a tight bond with an overlaidsilicone coated web (underlayment membrane), the adhesive/SBS flowinginto and bonding with the upper layer 144C (FIG. 14) of fibrousmaterial.

The silicone coating 148C may infuse into the upper layer 144C, which isnot infused with SBS, causing the silicone coating to surround thefibers of the layer 144C, which causes a reinforcement of the siliconecoating 148C and an interlocked interface in layer 150G (FIG. 15). Thesilicone coating 148C may be prepared and applied as described above inreference to the embodiment of FIGS. 1-8, starting with a commerciallyavailable moisture-curable silicone coating, such as Eterna-Kote S-100Silicone Roof Coating available from Sun Paints and Coatings Inc. ofClearwater, Fla. or similar coating from other commercial sources andmodifying it for application and rapid curing as described above,resulting in the properties of the coating and underlayment materialdescribed above.

As in the previously described embodiment, the silicone coating 148C(FIG. 9) is applied only to the upper surface of the protected,self-adhesive web 144 (FIG. 14) and not on the selvedge edge 150SE. Asshown in FIG. 9, an atomizer station 152 with one or more atomizers152A, 152B, 152C are utilized to spray a mist of water on the web 150 ontop of the applied layer 150 (FIG. 15) of silicone coating 148C (FIG.9), as described above. The atomizers 152A, 152B, 152C mist the siliconecoating 148C applied to the web 150 with water in order to speed up thecuring reaction of the coating. The curing reaction (polymerization) iscatalyzed by water, so therefore a fine water spray is effective atinducing an even and complete cure of the coating 148C. One or moresupport rolls 154, belts or other support mechanism(s) maintains theposition of the silicone coated web 150 relative to the atomizers 152A-Cand relative to a drying/cooling station 156 with one or more fans156A-E. The fans 156A-E will be used to evaporate remaining moistureafter the coating curing reaction has been completed. Optionally, an airknife may be used to drive water off the silicone coated web 150.

Additional support/redirecting rolls 158, 160 may be used to adjust thelength of the run of the silicone coated web 150 to allow curing of thesilicone coating 148C and to deliver the web 150 to a take-uproll/winder 162. Is should be appreciated that the system 110 of FIG. 9is not to scale and that the distances between elements 114, 118, 124,128, etc. may be of a different scale that that shown. In one example,the distance from the silicone coating station 148 to the atomizerstation 152 is a short distance, e.g., from about 2 to 3 feet to allowthe water mist time to cure the silicone coating 148C. In oneembodiment, the atomizer station 152 is about 6 to 8 feet long. Given aline speed of about 100-300 ft. per minute, in one example, the coatingis misted within 1 to 5 seconds after being applied to the siliconecoated web 150 and for a duration of about 5 to 10 seconds or in a linedistance of less than 500 ft. at 300 ft./min. or 160 ft. at a line speedof 100 ft./min. This misting results in rapid curing of the coating,e.g., in less than 100 seconds. After misting/curing, the web is driveninto the cooling/drying section 156. In this manner, the presentdisclosure illustrates how a silicone coated web 150 can be produced ina high speed (100 to 300 feet per minute) manufacturing environment. Thesilicone coating 148C is compatible and binds to the mat 112 material,as well as to SBS.

FIG. 15 shows the silicone coated web 150 in cross-section and featuringan upper layer 150C of un-infused mat, a lower layer 150B of SBS, aninfused middle layer 150D, a bottom adhesive layer 150E, a bottomrelease film 150F covering bottom adhesive layer 150E and a siliconecoating layer 150G. The selvedge edge 150SE is uncoated by siliconelayer 150G, allowing the open fibers of the un-infused mat 150C to beimpressed into and bind with an adhesive layer 150F and/or the SBS layer150E of an overlying web 150. If the layer 150C is fully infused withSBS, the adhesive layer 150E of an overlying layer will still stick tothe selvedge edge 150SE, but will not display the dynamic of interactingwith open fibers of layer 150C.

FIG. 16 shows a manufacturing line 210 for making an underlaymentmaterial 250 in accordance with an alternative embodiment of the presentdisclosure. A woven or felted polyester mat 212, having an initialthickness of about 0.5 mm to 1.6 mm or, in one embodiment, 0.8 mm to 1.2mm, and a density of about 40 g/m² to 250 g/m² or, in one embodiment,120 g/m² to 190 g/m² and a width of about 32 in to 42 in or, in oneembodiment, 1 m to 36 in., is withdrawn from a supply roll 214 by theaction of one or more rolls 216, 218A, 224A, 224B, 227A, 227B, 228A,229A, 229B, 234A, 234B, 246, 248A, 248B, 254, 258, 260, 262, which maybe driven by an electric motor or the like, and/or turned by the passageof the mat 212 passing there over. FIGS. 17 and 18 show across-sectional view of a final underlayment 250 with mat 112A (inunsaturated condition) and 212B (saturated condition). The mat 212,which is essentially the same as that depicted in FIG. 2 and which maybe obtained from Johns Manville of Denver, Colo., USA as productsidentified as spunbond/needle punched and/or glass reinforced mat, orfrom a variety of other sources. As an alternative to polyester, the mat212 may be made from other materials, such as fiberglass, a combinationof fiberglass and polyester, asphalt saturated felt-paper,polypropylene, polyethylene, or a combination of polypropylene andpolyethylene. Some or all of the rolls 216, 218A, 224A, 224B, 2227A,227B, etc., may be free-wheeling. Rolls, such as support rolls 216 and254, may be used to support the mat 212 as it travels a distance to thenext set of rolls or station, e.g., 218. Rolls 246, 258 and 260 may beused to change the direction of the mat 212, induce advancement of themat 212 and/or provide tensioning. In addition to rolls, e.g., 216,additional rolls, support belts, tables, etc. (not shown) may also beused in guiding, supporting and handling the mat 212, both at theinitial stage and at later stages.

As shown in FIG. 16, the manufacturing line 210 may be operated indifferent modes. For example, after withdrawal from the supply roll 214,the mat 212 may pass to a styrene butadiene styrene (SBS) modifiedasphalt coating/saturation station 218 by passing under roll 218A, whichdraws the mat 212 under the surface of liquefied coating 218C held inreservoir 218D. After saturation with SBS, the mat 212 achievessaturation state 212B. The saturated mat 212B is then passed throughsqueeze rollers 224A, 224B which conforms the mat 212B to specificdimensions and removes excess SBS material 218C, which drips back intothe reservoir 218D.

In the alternative, the mat 212 may bypass the SBS saturation station218, as indicated by mat portion 212A drawn in dotted lines, and bedrawn directly through the squeeze rolls 224A, 224B, such that it isunsaturated by SBS. The foregoing options of saturation ornon-saturation of the mat 212 are depicted in the underlayment 250 shownin FIG. 17, where a portion 212A is unsaturated and a saturated versionis shown as layer 212B. This is for simplicity of illustration, in thatan actual underlayment 250 would typically have one option or the other,but not both. After the mat 212A or 212B passes through squeeze rollstation 224, an SBS application station 225 may selectively apply alayer of SBS 225A to the top of the unsaturated mat 212A or optionallythe saturated mat 212B. This layer is then dimensioned by calendarrolling station 227 having rolls 227A, 227B that induce excess SBSmaterial 225A to be removed from the top surface of the mat 212A, 212Band drip back into the reservoir 218D. The foregoing step results in atop layer of SBS 270, as shown in FIGS. 17 and 18. Optionally, the toplayer of SBS 270 may be scraped by a knife 227D to remove SBS along awidth of e.g., 3 inches at one edge of the coated mat 212A/212B tocreate a recessed selvedge edge. In another alternative approach, theselvedge edge is not scraped. The SBS modified asphalt coating is of atype that is well known in the industry and may be obtained commerciallyor may be produced on site. The SBS modified asphalt coating 218C, 225Ais kept in a flowable state by maintaining it at a temperature of about325-380° F.

An adhesive applying station 228 with applying rolls 228A, 228B may beused to apply self-adhering adhesive (SA) 228C held in reservoir 228D tothe compressed mat 212A/212B yielding an adhesive coated web. FIGS. 17and 18 show a layer 272 of adhesive 228C (FIG. 16) on the bottom of theunderlayment 250. The adhesive 228C may be prepared on-site by combiningSBS rubber and asphalt or may be obtained commercially from a variety ofsources, e.g., from Crafco, Inc. of Chandler, Ariz. A filler may beadded to increase durability. In one exemplary embodiment, the adhesivewill have the following weight percentages: about 4% to 8% SBS rubber,about 50% to 60% asphalt of the 150-200 pen type and about 15% to 25%filler in the form of calcium carbonate/limestone.

Optionally, an adhesive 230A may be applied to the selvedge edge 250SE(FIG. 18) at adhesive applying station 230 and smoothed and dimensionedby blade 230B, excess adhesive 230A dripping off into receptacle 230C.FIG. 18 shows an optional layer 276 of selvedge edge adhesive 230A. Inanother alternative approach, no selvedge edge adhesive 230A/276 isused, such that the bottom adhesive layer 272 of a first sheet ofunderlayment 250 adheres to the top layer of SBS 270 at the selvedgeedge 250SE.

Referring to FIG. 16, after application of the adhesive 228C andoptionally 230A, the adhesive coated web 231 may be cooled by a coolingstation 231A, such as a water bath or other cooling apparatus, such as ablower, producing cooled, coated mat 232. A release film applicationstation 234 with application rolls 234A, 234B, 234C (optional) may beused to apply a split, siliconized, polyethylene bottom release film 236of about 1.0 to 1.5 mm in thickness to cover the bottom adhesive layer272 and optionally the selvedge edge 250E, producing protected,self-adhesive web 244. Siliconized, polyethylene release film isavailable from a variety of commercial sources, such as Integrated Filmsof Atlanta, Ga. and is deployed from a bottom film roll 238 and drawnwith the adhesive coated mat 232 between the rolls 234A, 234B. Asiliconized, polyethylene selvedge edge release film 240 drawn fromselvedge edge film roll 242 may optionally be similarly applied over theselvedge edge 250SE (FIG. 18) and optionally selvedge edge adhesivelayer 276 and pressed into position by rolls 234B, 234C, producingprotected, self-adhesive web 244. A release layer 274B is shown on theselvedge edge 250SE of underlayment 250 in FIG. 18. The release layer274B may be used to protect the adhesive layer 276 or the SBS layer 270at the selvedge edge 250SE, e.g., to prevent debris from sticking at theselvedge edge that would otherwise degrade the bonding and flatness ofthe overlapping sheet of underlayment 250 at the selvedge edge 250SE. Asshown in FIGS. 17 and 18, the underlayment 250 has a release film 274Acovering the bottom adhesive layer 272.

Referring to FIG. 16, the protected, self-adhesive web 244 optionallypasses over a support/direction change roll 246 and into a siliconecoating station 248 with a lower support roll 248B and an upper coatingroll 248A that applies a silicone coating 248C to a portion of the uppersurface 244C of the self-adhesive web 244 to yield a silicone coated web250. Only a portion of the width of the self-adhesive web 244 is coatedwith silicone and the portion that remains uncoated forms a selvedgeedge 250SE. Since the selvedge edge 250SE is uncoated with siliconecoating, it will form a tight bond with an overlaid silicone coated web(underlayment membrane) 250.

The silicone coating 248C may be prepared and applied as described abovein reference to the embodiment of FIGS. 1-8, starting with acommercially available moisture-curable silicone coating, such asEterna-Kote S-100 Silicone Roof Coating available from Sun Paints andCoatings Inc. of Clearwater, Fla. or similar coating from othercommercial sources and modifying it for application and rapid curing asdescribed above, resulting in the properties of the coating andunderlayment material described above.

As in the previously described embodiment, the silicone coating 248C(FIG. 16) is applied only to the upper surface of the protected,self-adhesive web 244 and not on the selvedge edge 250SE. As shown inFIG. 16, an atomizer station 252 with one or more atomizers 252A, 252B,252C are utilized to spray a mist of water on the web 250 on top of theapplied silicone layer 278 (FIGS. 17 and 18) of silicone coating 248C,as described above. The atomizers 252A, 252B, 252C mist the siliconecoating 248C applied to the web 250 with water in order to speed up thecuring reaction of the coating. The curing reaction (polymerization) iscatalyzed by water, so therefore a fine water spray is effective atinducing an even and complete cure of the coating 248C. One or moresupport rolls 254, belts or other support mechanism(s) maintains theposition of the silicone coated web 250 relative to the atomizers 252A-Cand relative to a drying/cooling station 256 with one or more fans256A-E. The fans 256A-E will be used to evaporate remaining moistureafter the coating curing reaction has been completed. Optionally, an airknife may be used to drive water off the silicone coated web 250.

Additional support/redirecting rolls 258, 260 may be used to adjust thelength of the run of the silicone coated web 250 to allow curing of thesilicone coating 248C and to deliver the web 250 to a take-uproll/winder 262. Is should be appreciated that the system 210 of FIG. 16is not to scale and that the distances between elements 214, 218, 224,228, etc. may be of a different scale that that shown. In one example,the distance from the silicone coating station 248 to the atomizerstation 252 is a short distance, e.g., from about 2 to 3 feet to allowthe water mist time to cure the silicone coating 248C. In oneembodiment, the atomizer station 252 is about 6 to 8 feet long. Given aline speed of about 100-300 ft. per minute, in one example, the coatingis misted within 1 to 5 seconds after being applied to the siliconecoated web 250 and for a duration of about 5 to 10 seconds or in a linedistance of less than 500 ft. at 300 ft./min. or 160 ft. at a line speedof 100 ft./min. This misting results in rapid curing of the coating,e.g., in less than 100 seconds. After misting/curing, the web is driveninto the cooling/drying section 256. In this manner, the presentdisclosure illustrates how a silicone coated web 250 can be produced ina high speed (100 to 300 feet per minute) manufacturing environment. Thesilicone coating 248C is compatible with and binds to the mat 212material, as well as to SBS, e.g., layer 270 (FIGS. 17 and 18).

As yet a further option a release sheet layer 280 (FIGS. 17 and 18) maybe applied over the silicone coating layer 278 to protect the siliconelayer 278, e.g., from dirt or other contamination during manufacture,packaging, storage, transportation to the site of application andapplication to a building surface. The release layer 280 and theapparatus used to apply the release layer 280 may like that explainedabove relative to the release layer applying station 234.

As can be appreciated by one of normal skill in the art, the siliconecoated web 50, 150, 250 can be utilized by positioning a suitably sizedlength of the silicone coated web 50, 150, 250 on roof decking. In theinstance of a sloped roof, the silicone coated web 50, 150, 250 isoriented with the bottom adhesive positioned proximate to the roofdecking with the selvedge edge 50AS, 150SE, 250SE at the higher portionof the roof decking (if sloped). The release film 50G, 150F, 274A isthen removed and the bottom adhesive layer 50E, 150E, 272 pressedagainst the roof decking to form an adhesive bond therewith. Once thefirst length of silicone coated web 50, 150, 250 is in place on theroof, a second length of silicone coated web 50, 150, 250 may be cut andplaced adjacent the first length, with an overlap occurring at theselvedge edge 50AS, 150SE, 250SE. Once in position relative to the firstlength of silicone coated web 50, 150, 250, the bottom release sheet50G, 150F, 274A may be removed from the second length of silicone coatedweb 50, 150, 250, such that the portion of the bottom adhesive 50E,150E, 272 of the second sheet that overlaps with the selvedge edge 50AS,150SE, 250SE of the first sheet firmly bonds with the adhesive 50D, 276on the selvedge edge 50AS, 250SE or with the fibers of the unsaturatedlayer 150C (or the SBS if the layer 150C is saturated) on the selvedgeedge 150SE in the case of the second embodiment, forming a water-tightbond. Optionally, nails or staples can be used to aid in fastening thelengths of silicone coated web 50, 150, 250 to the roof decking, e.g.,at the selvedge edge 50AS, 150SE, 250SE. Optionally, the release film50G, 150F, 274A on the bottom adhesive 50E, 150E, 272 may be dividedinto a plurality of portions, allowing a first portion to be removed andthe length of silicone coated web 50, 150, 250 affixed to the roofdecking followed by removal of a second portion. The foregoing processis repeated with overlapping lengths of silicone coated web 50, 150, 250at the selvedge edge 50AS, 150SE, 250SE until the roof decking iscovered with the underlayment.

After covering a roof deck with the silicone coated web 50, 150, 250underlayment described herein, a top layer of roofing material, such astiles, or shakes may be applied to cover the underlayment. In anotheralternative, the underlayment may serve as an exterior roof surface,that is, the underlayment can be used by itself to cover a roof deck inone simple operation, i.e., by adhering the underlayment to the roofdecking as described in the paragraphs above. Use of the silicone coatedroof material 50, 150, 250 of the present disclosure is facilitated bythe possibility of producing it in thin dimensions, which translatesinto a low weight per square foot ratio of 0.10 lb/ft² to 1.0 lb/ft² or,in one embodiment, 0.10 lb/ft² to 0.55 lb/ft² The lower the weight ofthe roof material, the easier it is for workmen to transport thematerial to a roof and handle it for placement on and attachment to theroof.

An aspect of the present disclosure is the recognition that a roofingunderlayment may have multiple purposes and functions, i.e., includingthe functions of rendering a roof impenetrable to water when used as anunderlayment and functioning as a radiation barrier to decrease energytransfer from the environment to inside a building envelope when used asan underlayment or as an exterior finished roofing surface. Increasedrejection of heat from the sun translates into reduced cooling costs,e.g., air conditioning costs, particularly in hot, sunny climates. Inthis regard, the silicone coated web 50, 150, 250 described abovedemonstrates the following properties: water impermeability <4 perms andinitial reflectivity of 0.9. Another aspect of the present disclosure isthe identification of an underlayment material that may be manufacturedand used with reduced volatile organic compounds (VOCs). Morespecifically, the underlayment of the present disclosure may be madewith VOCs in the range of 0 g/L to 50 g/L.

It will be understood that the embodiments described herein are merelyexemplary and that a person skilled in the art may make many variationsand modifications without departing from the spirit and scope of thedisclosed subject matter and claims. For example, while the modifiedasphalt coating, e.g., 18D1, 18D2, 118D, 218C, 225A has been describedabove as being applied to the mat 12, 112, 212 prior to the siliconecoating, e.g., 48C, 148C, 248C, the order of application could bereversed. Namely, the silicone coating, e.g., 48C could be applied tothe mat 12 prior to the application of the asphalt coating 18D1.

While the asphalt coating, e.g., 18D1 has been described above ascontaining SBS (styrene-butadiene-styrene), other asphalt modifiers,such as APP (atactic polypropylene), SIS (styrene-isoprene-styrene), SEB(styrene ethylene butylene), SEBS (styrene-ethylene-butylene-styrene)and combinations of homo, block and co-polymers may be used. In anotheralternative, the asphalt coating, e.g., 18D1 may be unmodified. Each ofthe foregoing variations may be made in any of the embodiments shown anddescribed above in reference to FIGS. 1-18. All such variations andmodifications are intended to be included within the scope of thepresent disclosure and claims.

We claim:
 1. A method for making a building material, comprising thesteps of: providing a web of support material in a roll; withdrawing thesupport material from the roll; coating the support material with asilicone material; curing the silicone material to a non-tackycondition; winding the coated support material on a take-up roll.
 2. Themethod of claim 1, wherein the silicone material is water-curable andthe step of curing includes applying water to the silicone material. 3.The method of claim 2, further including allowing the water to remain incontact with the silicone material for a period of time that initiatescuring.
 4. The method of claim 3, further comprising the step ofremoving the water from the silicone material after initiation ofcuring.
 5. The method of claim 2, further comprising adding a catalystto the silicone material to increase the rate of curing.
 6. The methodof claim 5, wherein the catalyst is an organo-metallic compound.
 7. Themethod of claim 6, wherein the catalyst is dibutylin dilaurate presentin a concentration of 0.1 to 1.0% by weight in the silicone material. 8.The method of claim 1, wherein the silicone material is applied at athickness in the range of 0.1 mm to 2 mm.
 9. The method of claim 1,wherein the silicone material has a viscosity in the range of 1,000 to20,000 cps during the step of applying,
 10. The method of claim 1,further comprising the step of applying a modified asphalt to thesupport material prior to the step of coating with the silicone coating.11. The method of claim 10, wherein the modified asphalt is imbeddedinto the support material by dip-saturation or squeezing prior to thestep of coating with the silicone material.
 12. The method of claim 10,wherein the modified asphalt is applied to an upper surface of thesupport material.
 13. The method of claim 1, further comprising applyingan adhesive to a bottom surface of the support material.
 14. The methodof claim 10, further comprising the step of forming a selvedge edge byscraping modified asphalt from a portion of the support material. 15.The method of claim 13, further comprising the step of applying arelease sheet to the adhesive applied to the bottom surface.
 16. Themethod of claim 1, wherein the silicone material is applied to a portionof the support material leaving a selvedge edge uncoated.
 17. The methodof claim 1, further comprising applying an adhesive to a selvedge edgeof the support material.
 18. The method of claim 17, further comprisingapplying a release sheet over the adhesive on the selvedge edge.
 19. Themethod of claim 1, wherein the silicone material is first prepared in anatmosphere of nitrogen prior to the step of applying the siliconecoating.
 20. The method of claim 1, wherein the step of applying andcuring are conducted on a roll line that advances at a rate of about 50to 300 feet per minute.
 21. The method of claim 20, wherein the curingoccurs within 10 minutes.
 22. The method of claim 4, wherein the step ofapplying water is by misting with a spray conducted in less than 10minutes.
 23. The method of claim 4, wherein the step of removing wateris conducted by blowing air on the building material.
 24. A buildingmaterial with an upper surface and a lower surface, comprising a supportweb at least partially infused with asphalt; a layer of siliconematerial applied to at least one of the support web or the asphalt,covering at least a portion of the upper surface and defining a selvedgeedge on the upper surface that is not covered by the silicone material.25. The building material of claim 24, wherein the asphalt is modifiedand contains at least one of SBS, APP, SIS, SEB, SEBS or a combinationof homo, block or co-polymers.
 26. The building material of claim 24,further comprising a layer of adhesive applied to a bottom surface. 27.The building material of claim 26, further comprising a release sheetremovably covering the adhesive on the bottom surface.
 28. The buildingmaterial of claim 24, wherein the support web is made from a fibrousmaterial.
 29. The building material of claim 28, wherein the fibrousmaterial includes at least one of polyester, fiberglass, a combinationof fiberglass and polyester, asphalt saturated felt-paper,Polypropylene, Polyethylene, or a combination of Polypropylene andPolyethylene.
 30. The building material of claim 24, wherein thebuilding material has a weight per square foot in the range of 0.1 to1.0 lbs./ft²
 31. The building material of claim 24, wherein the buildingmaterial has a weight per square foot in the range of 0.1 to 0.55lbs./ft².
 32. The building material of claim 24, wherein the buildingmaterial has the following properties: tensile strength MD/CD (psi)66/30; elongation MD/CD (%) 226/275; density of about 0.971 bs/yard²;tear strength MD/CD(psi) of 55/85 and adhesion to plywood(plf)) of about28.
 33. The method of claim 1, further comprising the step of applying amodified asphalt to the support material after the step of coating withthe silicone coating.
 34. The building material of claim 24, wherein theasphalt is un-modified.